Dodge Aspen/Volare 1976-1980 Repair Guide

Timing Cover and Chain

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Check the slack in the chain after installation.

REMOVAL & INSTALLATION





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Fig. Fig. 1 To remove the timing cover and/or chain, first remove the outermost pulley attaching bolts ...



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Fig. Fig. 2 ... then disengage the pulley from the alignment dowels and remove it



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Fig. Fig. 3 Using a puller to remove the vibration damper



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Fig. Fig. 4 Assemble a puller to the vibration damper ...



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Fig. Fig. 5 ... and remove the damper from the crankshaft snout



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Fig. Fig. 6 Remove the timing cover-to-engine block attaching bolts ...



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Fig. Fig. 7 ... and the oil pan-to-timing cover bolts



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Fig. Fig. 8 Pull the cover from the engine. Some gentle prying may be necessary to break the gasket seal



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Fig. Fig. 9 Make sure that the engine is at TDC by aligning the sprocket timing marks (arrows)



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Fig. Fig. 10 To remove the chain and sprockets, loosen the cam sprocket bolt ...



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Fig. Fig. 11 ... then remove it



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Fig. Fig. 12 Pull the cam sprocket off of the camshaft end and remove it and the chain as an assembly



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Fig. Fig. 13 Use a jawed puller to remove the crankshaft sprocket



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Fig. Fig. 14 Timing chain sprocket alignment and timing marks on the 225 cu. in. 6-cylinder engine



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Fig. Fig. 15 Timing chain sprocket alignment and timing marks on the 318 and 360 cu. in. 8-cylinder engine



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Fig. Fig. 16 Installing the vibration damper using tool C-3688 or equivalent

Six-Cylinder Engine
  1. Drain the cooling system and disconnect the battery.
  2.  
  3. Remove the radiator and fan.
  4.  
  5. With a puller, remove the vibration damper.
  6.  
  7. Loosen the oil pan bolts to allow clearance, and remove the timing case cover and gasket.
  8.  
  9. Slide the crankshaft oil slinger off the front of the crankshaft.
  10.  
  11. Remove the camshaft sprocket bolt.
  12.  
  13. Remove the timing chain with the camshaft sprocket.
  14.  

To install:

  1. Turn the crankshaft to line up the timing mark on the crankshaft sprocket with the centerline of the camshaft (without the chain).
  2.  
  3. Install the camshaft sprocket and chain Align the timing marks.
  4.  
  5. Tighten the camshaft sprocket bolt to 35 ft. lbs.
  6.  
  7. Replace the oil slinger.
  8.  
  9. Reinstall the timing case cover with a new gasket and tighten the bolts to 17 ft. lbs. Retighten the engine oil pan to 17 ft. lbs.
  10.  
  11. Press the vibration damper back on.
  12.  
  13. Replace the radiator and hoses.
  14.  
  15. Refill the cooling system.
  16.  

V8 Engines
  1. Disconnect the battery and drain the cooling system.
  2.  
  3. Remove the vibration damper pulley. Unbolt and remove the vibration damper with a puller. Remove the fuel lines and fuel pump, then loosen the oil pan bolts and remove the front bolt on each side.
  4.  
  5. Remove the timing gear cover and the crankshaft oil slinger.
  6.  
  7. Remove the camshaft sprocket lockbolt, securing cup washer, and fuel pump eccentric. Remove the timing chain with both sprockets.
  8.  

To install:

  1. Place the camshaft and crankshaft sprockets on a flat surface with the timing indicators on an imaginary centerline through both sprocket bores. Place the timing chain around both sprockets. Be sure that the timing marks are in alignment.
  2.  


WARNING
When installing the timing chain, have an assistant support the camshaft with a screwdriver to prevent it from contacting the freeze plug in the rear of the engine block. Remove the distributor and the oil pump/distributor drive gear. Position the screwdriver against the rear side of the cam gear and be careful not to damage the cam lobes.

  1. Turn the crankshaft and camshaft to align them with the keyway location in the crankshaft sprocket and the keyway or dowel hole in the camshaft sprocket.
  2.  
  3. Lift the sprockets and timing chain while keeping the sprockets tight against the chain in the correct position. Slide both sprockets evenly onto their respective shafts.
  4.  
  5. Use a straightedge to measure the alignment of the sprocket timing marks. They must be perfectly aligned.
  6.  
  7. Install the fuel pump eccentric, cup washer, and camshaft sprocket lockbolt, and torque to 35 ft. lbs. If camshaft end-play exceeds 0.010 in., install a new thrust plate. It should be 0.002-0.006 in. with the new plate.
  8.  

CHECKING TIMING CHAIN SLACK





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Fig. Fig. 17 Measuring the timing chain slack on the 225 cu. in. 6-cylinder engine



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Fig. Fig. 18 Measuring the timing chain slack on the 318 and 360 cu. in. 8-cylinder engines

  1. Position a scale next to the timing chain to detect any movement in the chain.
  2.  
  3. Place a torque wrench and socket on the camshaft sprocket attaching bolt. Apply either 30 ft. lbs. (if the cylinder heads are installed on the engine) or 15 ft. lbs. (cylinder heads removed) of force to the bolt and rotate the bolt in the direction of crankshaft rotation in order to remove all slack from the chain.
  4.  
  5. While applying torque to the camshaft sprocket bolt, the crankshaft should not be allowed to rotate. It may be necessary to block the crankshaft to prevent rotation.
  6.  
  7. Position the scale over the edge of a timing chain link and apply an equal amount of torque in the opposite direction. If the movement of the chain exceeds 1 / 8 in., replace the chain.
  8.  

TIMING GEAR COVER SEAL REPLACEMENT





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Fig. Fig. 19 Removing the front oil seal



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Fig. Fig. 20 Installing a new front oil seal

A seal remover and installer tool is required to prevent seal damage.

  1. Using a seal puller, separate the seal from the retainer.
  2.  
  3. Pull the seal from the case.
  4.  
  5. To install the seal place it face down in the case with the seal lips downward.
  6.  
  7. Seat the seal tightly against the cover face. There should be a maximum clearance of .0014 in. between the seal and the cover. Be careful not to overcompress the seal.
  8.  

 
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